Industrial Engineering Applications of Rapid Prototyping Dr. Denis Cormier Rochester Institute of Technology Department of Industrial and Systems Engineering
Introductions 1995-2009 North Carolina State University 2009-present Rochester Institute of Technology Involved in RP industry since 1996 Rapid Prototyping Journal editorial advisory board ASTM F-42 standards group founding member Contributor to NSF, Navy, Air Force additive manufacturing roadmap efforts
What Is Rapid Prototyping? a.k.a. additive manufacturing, 3D printing, solid freeform fabrication, digital printing, rapid manufacturing, etc. A family of fabrication processes that use layer additive manufacturing Key is that parts of any complexity are made without molds or dies RP allows a part to be made in hours or days
Quick Overview of Selected AM Processes
AM Processes for Polymer Parts Stereolithography (3D Systems) Laser sweeps over liquid polymer vat to selectively harden one layer of resin at a time www.youtube.com/watch?v=vqj 96SxDnXA Fused Deposition Modeling (Stratasys, MakerBot, Bits-from- Bytes, etc) Molten thermoplastic is extruded through a moving nozzle http://www.youtube.com/watch?v =ykhmmkqdi68 Skull and implant model Printed on FDM machine
AM Processes for Polymer Parts Selective Laser Sintering (3D Systems, EOSint) Scan a laser over selected regions of a layer of powder to melt the powder http://www.youtube.com/watch?v=kkkdhlqaihs Inkjet Printed Photopolymers (Objet, 3D Systems) Inkjet print photopolymer where you want it, and then cure it with UV light http://www.youtube.com/watch?v=0lzoyldw7je Nylon lattice structure printed via SLS Multimaterial ink jetted photopolymer component
AM Processes for Metal Parts Selective Laser Melting (EOS, Concept Laser, etc) Laser is selectively scanned over layer of metal powder http://www.youtube.com/wa tch?v=afdjy-4uhse Electron Beam Melting (Arcam) E-beam is selectively scanned over layer of metal powder http://www.youtube.com/watch?v=e7--zwpvvdq Bronze infiltrated steel chess piece Titanium components produced via EBM
AM of COLOR Parts 3D Printing (ZCorp) Inkjet print color binder onto thin layers of plaster http://www.youtube.com/w atch?v=21rluhsni6q
Summary: What Makes AM Processes Different? Geometry is free DFM rules effectively go away Functionally graded materials (someday) Ability to produce parts having enhanced material properties Titanium auxetic lattice structures produced via EBM (Credit: Li Yang)
Industrial Engineering Applications of RP/AM Some obvious and some not so obvious
Production Economics Fixed vs. variable costs Conventional processes include fixed tooling costs as well as variable per-part costs (material, labor, etc) Tooling costs are amortized over the total quantity of parts produced AM processes eliminate fixed tooling costs At low production quantities, the elimination of tooling costs is significant Source: Hopkinson and Dickens, Proc. Instn Mech. Engrs Vol. 217 Part C: J. Mechanical Engineering Science
Ergonomics Form, fit, feel, and function Prototype parts in user focus groups EU CustomFIT Project Running shoes Motorcycle seat Customized consumer goods Eyeglasses (nose bridge) Swimming goggles Helmets Office seating etc. http://utwired.utexas.edu/lff/symposium/ proceedingsarchive/pubs/ Manuscripts/2009/2009-57-Jones.pdf
Assembly Jigs and Fixtures Assembly fixtures are typically produced in lots of one AM process may be faster/cheaper than machining AM process can produce nonmachinable geometries Error proofing Color and text Arrows or other 3D annotations printed right into the fixtures to reduce assembly errors
Objective: Improve quality and reduce cost of orthopedic health care Improved fit vs. mass produced bone implants Impact on cost of health care? Reduce surgical time Custom Implants and Surgical Drilling/Cutting Guides Pre-fabricated plates/guides vs. forming bone plates during surgery Locate drill holes at optimal locations Reduce surgical complications Credit: Mr. Ketan Jajal
Presurgical Planning Create 3D models from CT/MRI scan data Fabricate physical models Models used for: Presurgical planning Communication with patient
Component Unitization DFA guidelines Separate parts needed for relative motion, different materials, etc. Multiple parts are often used due to DFM guidelines DFM essentially doesn t apply when we make parts via additive manufacturing Component unitization Merge parts that would have been produced separately due to DFM guidelines Advantages Fewer parts and assembly steps Enhanced reliability in some cases Challenge mechanical designers will need to reconsider how parts are made to take advantage of the possibilities Titanium EBM parts
Concurrent engineering Short runs of parts for assembly line design Design and refine assembly line and assembly stations while production tooling is being produced Pilot production runs Time and motion studies Line balancing Ergonomics Work station design Assembly training Assembly Line Applications
Short Run Tooling Direct tooling Molds/dies Vacuum thermoforming tools InVisalign Braces
Short Run Tooling Indirect tooling Sand casting patterns Wax investment casting patterns Examples: Jewelry and minimally invasive surgical instruments Custom investment cast bronze drawer pull Investment cast aluminum suturing device
Rapid Manufacturing of Functional Parts Small production quantities Mass Customization Medical parts High dollar value parts Aerospace components, exotic materials that need to be near net shape, etc. Example: Custom hearing aids made using FDA-approved polymers Electroless nickel plated stereolithography air pump housing Steel turbine produced via SLM process
Impact of AM On Logistics (someday) Distributed vs. centralized manufacturing Centralized manufacturing high tooling costs dictate that parts are made in high volumes at 1-2 central locations and then shipped to finished goods warehouses Distributed manufacturing elimination of tooling allows parts to be produced close to the point of use on demand
Impact of AM On Logistics Reduce or eliminate finished goods warehouses for discontinued products Reduce inventory carrying costs Dollar investment in finished goods Land, electricity, HVAC, maintenance, etc. Product damage Product obsolescence Reinvest inventory funds in modernization and efficiency upgrades Potential environmental impacts Material utilization Tooling Transportation
Rapid Manufacturing of the Future? Digital libraries of spare/replacement parts Go online and select make/model/year/part Customize the part (optional) Enter payment info Click Print Part prints out at your local 3D copy shop, or even in your own home Concerns Much discussion about digital rights management for 3D models
Questions and/or Discussion? Feel free to contact me if you have questions/comments on this topic: Denis Cormier at cormier@mail.rit.edu